JP4897260B2 - Decorative multi-layer coextrusion molding - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a synthetic resin co-extruded multilayer molded body used as an interior / exterior material of a building material, and more particularly to a decorative multilayer co-extruded molded body having a grain pattern.

A variety of surface decorative molded articles having a grain pattern, a stone pattern, etc. are used as interior / exterior materials for houses, indoor unit baths, counter members for kitchens, and the like. The production method of these products is roughly divided. The method of applying a wood grain pattern by a post-process, such as printing a wood grain pattern on the surface of a molded body or sticking a wood grain pattern sheet, and a surface material having a pattern on the substrate There are methods of simultaneously performing the production of a molded body and the application of a pattern, such as coating the surface layer made of a transparent resin as a protective layer on a substrate having a pattern or a substrate having a pattern. In recent years, patterning by coextrusion molding is often used in order to avoid complicated post-processes. In particular, when a wood grain pattern is to be applied, the surface is formed by dispersing a mineral powder such as mica in a transparent or opaque synthetic resin or by unevenly dispersing dyes or pigments. Layer, which is laminated on a base layer made of, for example, a low-foamed or non-foamed synthetic resin (Patent Document 1), a first surface layer resin, a second surface layer resin, and a base material resin, and in the first surface layer resin What mixes the mixture which non-uniformly mixed 2nd surface layer resin on base-material resin (patent document 2) etc. are used.
Japanese Patent Publication No. 07-119047 Japanese Patent Laid-Open No. 04-19816

  The methods disclosed in Patent Document 1 and Patent Document 2 use a method of mixing differently colored resins that are dispersed non-uniformly in a colored resin or a non-uniformly dispersed inorganic powder or the like. . The non-uniform dispersibility expresses excellent patterns such as wood grain. However, since the seed resin, that is, the so-called base resin, and a resin having different extrusion viscosity or melt viscosity are mixed in the colored resin, the depth of the decorative portion (for example, the wood grain portion or the annual ring portion) made of the seed material is sufficient. There is a problem that it is not obtained and lacks the expressiveness of natural and beautiful wood grain pattern. In addition, if the color of the seed resin is darker than that of the base resin, it is possible to develop a pattern such as wood grain, but conversely, if the base color is dark and the seed resin is light, The light color of the agent resin is erased to the dark color of the base resin, and there are cases where the pattern cannot be developed. In addition, a subtle shadow is seen in the wood grain pattern, but even the shadow cannot be expressed by the method of the above-mentioned patent document. Furthermore, a composite of a grain pattern and other patterns, for example, a composite of a grain pattern and a stripe pattern, a composite of a grain pattern and a stone pattern, etc. cannot be expressed by the conventional method.

  In view of the above problems, the present invention is capable of expressing a deep wood grain pattern, a shaded wood grain expression, and even if the color of the seed is difficult to express, such as a light color. Providing a molded product that can be expressed, providing a molded product that can express the complexity of wood more, and that can be combined with other patterns such as stripe patterns, stone patterns, etc. It is.

According to the present invention, the following inventions are provided.
1. (A) A decorative synthetic multilayer having at least two layers of a transparent synthetic resin layer or a translucent synthetic resin layer and having an outer layer having a decorative portion made of a seed resin, and (b) an inner layer made of a colored synthetic resin layer A decorative multi-layer coextrusion molding having a grain pattern, which is a coextrusion molded body and has a light-colored decorative part made of the seed resin compared to the colored resin layer of the inner layer (b) body.
2. (A) a transparent synthetic resin layer or a translucent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a group made of a thermoplastic synthetic resin A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern.
3. (A) a transparent synthetic resin layer or a translucent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a base made of a metal core material A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern.
4). (A) a transparent synthetic resin layer or a semi-transparent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a base made of an inorganic core material A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern.
5). (A) a transparent synthetic resin layer or a translucent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a base made of an organic core material A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern.
6). 2. The decorative multilayer coextrusion molded article having a wood grain pattern as described in 1 above, wherein the inner layer (b) is a low foam layer having an expansion ratio of 1.1 to 5.
7). 3. The decorative multi-layer coextrusion molded article having a wood grain pattern as described in 2 above, wherein the base material layer (c) is a low foam layer having an expansion ratio of 1.1 to 5 times.
8). A decorative multilayer coextrusion molded article having a wood grain pattern according to any one of the above 1 to 7, wherein the cross-sectional shape is irregular.

  Since the decorative multilayer coextrusion molded product of the present invention comprises at least two layers of an outer layer having a decorative portion made of a seed resin and an inner layer made of a colored synthetic resin layer or a decorative synthetic resin layer, It is possible to express a sense of grain and to express a subtle shade. Furthermore, even if the color of the seed agent is lighter than the color of the inner layer, the decorative portion can be expressed on the surface of the molded body without losing the color of the inner layer (dark color). Moreover, in addition to the outer layer which has the decoration part which consists of seed resin, and the inner layer which consists of a colored synthetic resin layer or a decorative synthetic resin layer, a thermoplastic synthetic resin, a metal core material, an inorganic core material, or an organic core material In addition to the wood grain pattern, a composite pattern with a stone pattern, a stripe pattern, or the like is possible as long as the molded body is composed of at least three layers of the base material layer.

Best Mode for Carrying Out the Invention

  The decorative multilayer coextrusion molded product of the present invention comprises at least two layers: an outer layer having a decorative portion made of a seed resin, and an inner layer made of a colored synthetic resin layer or a decorative synthetic resin layer.

  The inner layer in the present invention is made of a colored synthetic resin or a decorative synthetic resin. The type of synthetic resin to be used is not particularly limited, but an extrudable thermoplastic resin such as polyvinyl chloride resin (hereinafter referred to as PVC resin), acrylonitrile-butadiene-styrene copolymer resin (hereinafter referred to as ABS resin). ), Acrylonitrile-styrene-acrylic rubber copolymer resin (hereinafter referred to as ASA resin), polystyrene resin (hereinafter referred to as PS resin), high impact polystyrene resin (hereinafter referred to as HIPS resin), acrylonitrile-styrene copolymer resin (hereinafter referred to as “resin”). AS resin), modified polyphenylene ether resin, polyethylene resin, polypropylene resin, polymethyl methacrylate resin (hereinafter referred to as PMMA resin), methyl methacrylate-butyl acrylate copolymer resin, methyl methacrylate-styrene copolymer resin, Which acrylic resin, it can be selected from polyester resin or a mixed resin thereof. Particularly preferred from the viewpoints of moldability, toughness and economy are PVC resin, ABS resin and HIPS resin. These thermoplastic synthetic resins include fillers such as calcium carbonate, talc, mica, and shirasu balloons, lightweight materials, reinforcing materials such as glass fibers and cellulose fibers, flame retardants, other thermal stabilizers, lubricants, etc. Various additives added to the resin molded body can be included. Moreover, in order to express a wooden texture more, you may mix wood powder etc. in the high ratio of 50% or more.

The inner layer may be a non-foamed layer, but in order to impart processability and lightness, a foaming agent may be added to form a low foamed layer. As the foaming agent that can be used, a solid foaming agent that decomposes at the extrusion temperature to generate a gas is preferable, and sodium bicarbonate, ammonium carbonate, azodicarboxylic acid amide, benzenesulfonyl hydrazide, or the like is used as such a foaming agent. Can do.
The expansion ratio is 1.1 to 5.0 times, preferably 1.5 to 3.0 times.

  The synthetic resin of the inner layer is colored or decorated. That is, when a wood grain pattern is expressed, coloring such as a brown color, a dark brown color, and a beige color, which are base colors, is performed by adding a colorant, for example. Moreover, when giving a composite pattern with a stone pattern, a stripe pattern, etc., a mica powder, a grain decoration part by a granular additive, a stripe decoration part by uneven | corrugated provision, etc. are given with respect to an inner layer.

  The outer layer in the present invention is a transparent synthetic resin layer or a translucent synthetic resin layer and has a decorative portion made of a seed resin. The synthetic resin layer is not particularly limited, and the same resin as the inner layer can be used. In view of the fact that it is a resin used on the surface side and transparency or translucency is required, acrylic resins such as PMMA resin, PS resin, transparent ABS, AS, ASA, and PVC are preferable. In order to impart various physical or chemical properties to the surface layer resin, various additives that are usually used in synthetic resins may be added within a range that does not impair the required transparency or translucency. In addition, as long as it is a transparent layer or a semi-transparent layer, it may be colored transparent, colored semi-transparent, or may be non-colored.

The thickness of the outer layer is about 0.1 to 3.0 mm, preferably 0.3 to 1.0 mm. If the thickness is 0.1 mm or less, it is difficult to give a stable pattern. If the thickness is 3.0 mm or more, the effect is not changed, but it is economically disadvantageous, and uniform lamination is difficult.

  A seed agent is added to the outer layer to form a decorative portion. The seed resin is preferably a resin having a lower MFR value than a synthetic resin (hereinafter referred to as an outer layer base resin) used as the outer layer resin. Since the seed resin has lower fluidity than the outer layer base resin, it does not mix uniformly with the outer layer base color resin in the extrusion molding kneading process. In addition, a streak pattern or a marble pattern with unclear boundaries can be formed to give an appearance similar to a wood grain. Usually, the seed is originally blended in the same layer as the colored inner layer as a grain pattern, but in the present invention, it is essential to blend the seed in the outer layer, not the colored or decorative inner layer. As a result, it is possible to express a deep grain feeling and to express a subtle shadow feeling. Also, if the colored inner layer is dark and the seed is light, if the seed is blended in the same layer, the shade of the light part will be lost to the dark part and the light stripe pattern However, by adding a seed agent to the outer layer, it becomes possible to sufficiently express a streak pattern even if the seed agent is light in color. Furthermore, since the outer layer containing the seed agent is a transparent or translucent layer, the inner layer can also be expressed through the outer layer when the molded body is viewed from the surface side. That is, a beautiful pattern can be expressed by superposing the outer layer and the inner layer. In addition, in this invention, although a seed agent is mix | blended with an outer layer, mix | blending a seed agent with an inner layer is not excluded, You may mix | blend a seed agent with an inner layer in addition to an outer layer.

  The type of resin used as a seed agent is not particularly limited, but AS resin, ABS resin, ASA resin, PMMA resin, and the like correspond to this, and particularly preferably an acrylic thermoplastic resin such as an ASA resin. is there. In addition, a general inorganic pigment having excellent weather resistance is used as a colorant for the seed resin. The mixing ratio of the seed resin to the outer layer base resin is preferably about 0.2 to 10% by weight, more preferably about 0.5 to 5% by weight, based on the outer layer base color resin.

  In the present invention, in addition to the two layers of the inner layer and the outer layer, a layer structure can be further added. For example, it has a three-layer configuration of an outer layer, an inner layer, and a base material layer. As the base material layer, the same resin material as that of the inner layer can be used. Moreover, since coloring and decorating are not required, a wide variety of materials can be selected. In addition, when using a base material layer, it is preferable to make the said base material layer into a foamed layer by adding the foaming agent described in the place of the said inner layer. Regarding the expansion ratio, a low foam layer of 1.1 to 5.0 times is preferable. When the base layer is a low foam layer, the inner layer is preferably a non-foam layer. The thickness of the base material layer is preferably about 5.0 mm to 30 mm in view of workability and lightness. Moreover, the thickness of the inner layer in the case of providing a base material layer is 0.2 to 3.0 mm, preferably 0.5 to 1.5 mm. If the thickness is 0.2 mm or less, a deep pattern cannot be stably expressed. On the other hand, if the thickness is 3.0 mm or more, the processability as a multilayer molded article is impaired, and it is laminated on the base material layer uniformly. Becomes difficult.

Furthermore, a metal core material, an inorganic core material, or an organic core material can also be used as a material of the base material layer.
As the metal core material, various metals such as stainless steel, aluminum, an aluminum alloy, and galvanized steel can be used. From the viewpoint of lightness and workability, an aluminum alloy is preferable. As the inorganic core material, a ceramic material, a foamed ceramic material, a cement-based molded body, or the like can be used. As the organic core material, a thermosetting resin molded body, for example, a polyurethane molded body, an epoxy resin molded body, etc. can be used, and if the influence of the heating temperature at the time of extrusion molding does not occur so much, thermoplasticity It may be a resin molded body.

  In the present invention, in addition to the base material layer, a surface layer may be further provided, for example, by covering the surface side of the outer layer with a transparent acrylic resin, and adhesion between each outer layer, inner layer, base material layer, etc. An intermediate layer may be provided as long as the effects of the present invention are not impaired, such as providing a layer.

  In addition, about the lamination | stacking method, it is not necessary to provide an outer layer in the whole surface of an inner layer, For example, the structure which coat | covers an outer layer on an inner layer only in the part recognized by a user as an external appearance may be sufficient. That is, only the portion that requires decoration of the co-extruded product may be a multilayer structure. Similarly, it is not necessary to cover the entire surface of the base material layer with the inner layer and the outer layer, and it may be a laminated structure of only one surface or a part that requires decoration.

  The shape of the molded body in the present invention is not particularly limited, and is not limited to a flat plate shape, and may be an irregular shape such as an L shape or a U shape, a hollow shape, a circular shape, or the like.

The decorative multi-layer coextrusion molded product of the present invention is formed in one die by a multi-layer extrusion molding method as shown in FIG. 2 or FIG. 3 in terms of productivity, long product molding, and constant product characteristics. It is manufactured by a coextrusion molding method such as laminating each resin. Co-extrusion molding can be carried out by a conventional co-extrusion molding method by appropriately using a conventional resin co-extrusion molding, for example, the Celca method.

Hereinafter, the present invention will be described in more detail and specifically by way of examples.
Example 1
The outer layer, inner layer and substrate layer compounds were simultaneously extruded from the outer layer extruder, the inner layer extruder and the substrate layer extruder, respectively, and laminated in a die to form a three-layer extruded product. Extrusion conditions are as follows:
Extruder for base material layer: 45φ, extruder for inner layer of twin screw extruder: 40φ, extruder for outer layer of single screw extruder: 40φ, single screw extruder die: L-shaped profile (35mm × 120mm)
As the composition of the inner layer and the outer layer, the synthetic resins described in Table 1 were used. In this blending, the inner layer is colored and the seed is blended in the outer layer. In addition, a base material layer uses what mixed 2 weight part of baking soda as a foaming agent, and 10 weight part of talc as an inorganic filler with respect to 100 weight part of ABS resin (made by MG ABS).

By performing three-layer coextrusion molding as described above, a decorative multilayer coextrusion molded body having a surface grain pattern was obtained.

Examples 2-4, Comparative Example 1
A three-layer extruded product was obtained in the same manner as in Example 1 except that the synthetic resins for the inner layer and outer layer were those listed in Table 1. The resins used in Examples 1 to 4 and Comparative Example 1 are as follows:
PMMA resin: “Acrypet” manufactured by Mitsubishi Rayon Co., Ltd.
MS resin: “Cebian” manufactured by Daicel Chemical Industries, Ltd.
Seed (ASA resin): "UM Wood" manufactured by MG ABS

Example 5
The outer layer and inner layer compounds were simultaneously extruded from the outer layer extruder and the inner layer extruder, respectively, and further an anodized aluminum alloy core material (hollow tubular: outer diameter 30 mm, metal part thickness 3 mm, A6063S-T5) was inserted into the die from the rear side and laminated in the die to form a three-layer extruded product. Extrusion conditions are as follows:
Inner layer extruder: 40φ, single screw extruder Outer layer extruder: 40φ, single screw extruder The inner layer and the outer layer were blended in the same manner as in Example 2. In this blending, the inner layer is colored and the seed is blended in the outer layer.

Examples 6-7
A three-layer extrusion molded body was used under the same conditions as in Example 5 except that a hard polyurethane hollow tubular core material (Example 6) and a ceramic hollow tubular core material (Example 7) were used as the base material layer. Obtained.

Appearance evaluation Appearance evaluation of the decorative multilayer coextrusion molded bodies obtained in Examples and Comparative Examples was performed. In the molded body of Example 1, the streak pattern of the seed material of the outer layer was expressed without losing the dark color of the inner layer, and the wood grain pattern was expressed as the surface appearance. In the molded body of Example 2, a wood grain pattern was expressed, and a wood grain pattern with a shadow was obtained. In the molded body of Example 3, a complex streak pattern composed of two kinds of seeds was expressed, and a shadow was also observed. In the molded body of Example 4, a unique composite pattern having a streak pattern on a stone pattern was expressed. On the other hand, in the molded product obtained in Comparative Example 1, the light-colored streak pattern of the seed was lost to the resin color composed of the dark colorant, resulting in insufficient expression of the streak pattern and poor expression of the grain pattern. It was enough.
Moreover, also in the woodgrain coextruded molded body obtained in Example 5, Example 6 and Example 7, a molded body having a deep shading feeling was obtained.

: Schematic diagram showing the cross-sectional structure of the decorative multilayer coextrusion molded product of the present invention : Schematic diagram of coextrusion molding showing one example of molding method of decorative multi-layer coextrusion molding of the present invention : Schematic diagram of coextrusion molding showing another example of the molding method of the decorative multilayer coextrusion molding of the present invention

Explanation of symbols

1: outer layer 2: inner layer 3: base material layer A: outer layer extruder B: inner layer extruder C: base material layer extruder D: base material core material

Claims (8)

(A) A decorative synthetic multilayer having at least two layers of a transparent synthetic resin layer or a translucent synthetic resin layer and having an outer layer having a decorative portion made of a seed resin, and (b) an inner layer made of a colored synthetic resin layer A decorative multi-layer coextrusion molding having a grain pattern, which is a coextrusion molded body and has a light-colored decorative part made of the seed resin compared to the colored resin layer of the inner layer (b) body. (A) a transparent synthetic resin layer or a translucent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a group made of a thermoplastic synthetic resin A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern . (A) a transparent synthetic resin layer or a translucent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a base made of a metal core material A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern . (A) a transparent synthetic resin layer or a semi-transparent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a base made of an inorganic core material A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern . (A) a transparent synthetic resin layer or a translucent synthetic resin layer, an outer layer having a decorative portion made of a seed resin, (b) an inner layer made of a colored synthetic resin layer, and (c) a base made of an organic core material A decorative multi-layer coextrusion molded body having at least three layers of a material layer, wherein the decorative part made of the seed resin is lighter than the colored resin layer of the inner layer (b) A decorative multilayer coextrusion molded product having a wood grain pattern . The decorative multilayer coextrusion molded article having a wood grain pattern according to claim 1, wherein the inner layer (b) is a low foaming layer having a foaming ratio of 1.1 to 5 times. The decorative multi-layer coextrusion molded article having a wood grain pattern according to claim 2, wherein the base material layer (c) is a low foam layer having an expansion ratio of 1.1 to 5 times. The decorative multilayer coextrusion molded article having a wood grain pattern according to any one of claims 1 to 7 , wherein the cross-sectional shape is an irregular shape.

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